, _ _

.- ,

/ fUNITED STATES

8 NUCLEAR REGULATORY COMMISSIONo

g e REGION 11*m 101 MARIETTA ST., N.W., SUITE 3100

1ATLANTA, GEORGIA 30303o.....

Report Nos. 50-518/81-23, 50-519/81-23, 50-520/81-23, 50-521/81-23

Licensee: Tennessee Valley Authority500A Chestnut Street Tower IIChattanooga, TN 37401

Facility Name: Hartsville

Docket Nos. 50-518, 50-519, 50-520, 50-521

License Nos. CPPR-150, CPPR-151, CPPR-152, CPPR-153

Inspection at Hartsv lie site near Hartsville, Tennessee

Inspecto '/6 M!d3!8/-8. R. Crowl y Date Signed

Approved by:_ / h/4 M!D3[8/A. R. Hhrdt, Section Chief Date SignedEngineering Inspection Branch1:ngineering and Technical Inspection Division

SUMMARY

Inspection on December 1-4, 1981

Areas Inspected

This routine, unannounced inspection involved 28 inspector-hours on site in theareas of safety-related piping (Units Al and A2), steel structures and supports(Units Al and A2), previous inspection findings (Unit A1), and licensee identi-fied items (Units A1, A2, B1, and B2).

Results

,' No violations or deviations were identified.!

,

9a

8201270513 811224PDR ADUCK 050005180 PDR.

_

. ,

,.

.

c

REPORT DETAILS.

~

1. Persons Contacted

Licensee Employees

.

*R. T. Hathcote, Project Manager' *W T. Quinn, Construction Engineer

*H. S. Shepherd, Assistant Construction Engineer-QC*B. F. Painter, General Construction Superintendent*J. T. McGee, Engineering Management Assistant*J. W. Henry, Supervisor -_. Welding QC -

*T. L. Carden. Assistant Supervisor - Welding QC*H. F. Bates, Supervisor - Civil pE*J. W.- Davenport, Supervisor - Civil QC

,

G. N. Crawley, Welding Engineer - QC'

' L. R. Dicken, Engineering Associate - Welding QCW. K. Anders, OEDC - QA '

S. D. Love, ENDES, NEB-NLSS. Gray, PWR Regulatory Staff.

NRC Resident Inspector

*J. F. Schapker

j * Attended exit in'terview

2. Exit Interview5 Thefinspection scope and findings'were summarized on December 4, 1981 with

those persons indicated in paragraph I above.

3. Licensee Action on Previous Inspection Findings:i (Closed) Violation - 520/81-15-01, Failure to ' Follow Procedures for Stud

Welding. TVA letter of response dated September 28, 1981 has been reviewedand determined to be acceptable by Region II. The inspector held discus-sions with responsible licensee personnel and examined corrective actions asstated in the letter of response. The. inspector concluded that TVA had'E

determined the full extent of the subject violation, performed the necessary ;

follow-up actions to correct the present conditions and developed the-necessary corrective actions to preclude recurrence of similar circum-

. stances. The corrective actions identified in the letter of response havebeen implemented. -

4. Unresolved Items i

Unresolved items were _not identified during this inspection.

.. .

,

.

2

5. Independent Inspection Effort (Units Al and A2)

The inspector conducted a ger.eral inspection of the reactor. buildings,auxiliary buildings, .. fuel buildings, and control buildings to observeconstruction progress and construction activities such as welding, materialcontrol,' housekeeping, and storage.

Within'the areas inspected, no violations or deviations were identified.

6. Safety.Related Piping (Units Al aad A2).

'The inspector examined the work activities described below for safetyrelated piping to determine whether applicable code and procedure ' require-ments were being met. The applicable code for this welding is the-ASMEBoiler and Pressure Vessel Code, Section III, Subsections NC and ND,1974Edition with addenda through Summer 1974.

The inspector observed the following in prccess welds at the stages indi-cated:

WELD- SIZE CLASS UNIT STATUS

A2AHP0031003 16" X 1.031" IIIC2 A2 Repair grinding finalfor NDE

A1ARH0040R03 24" X .375" IIIC2 Al Welding fill passesAIArH0040015 S1 24" X .375" IIIC2 Al Welding fill passesA1ARH0130002 R2 18" X .562" IIIC2 Al Repair - in processA1FFC221001 8" X .322 IIIC3 Al Welding fill passes

The welding was examined to determine whether:

(1) Work is conducted in accoEdance with a document w51ch coordinates andsequences operations, references procedures, establishes hold points,and provides for production and inspection approval.

(2) Weld identification and location are as specified.

(3) Procedures, drawings, and .other instructions are at the work stationand readily available.

(4) WPS assignment is in acccrdance with applicable code requirements.

(5) Welding technique and sequence are specified and adhered to.

(6) Welding filler materials are the specified type and traceable .to.certification-

(7) Alignment of parts is as specified.

(8) Preheat and interpass temperatures are in accordance with' procedures.

. .

_.

3

(9) Electrodes are used in positions and with electrical characteristicsspecified.

(10) Shielding gas is in accordance with the welding procedures.

(11) Welding equipment is in good condition.

(12) Interpass cleaning is in accordance with applicable procedures._

(13) Temporary attachments are removed in accordance with applicable proce-dures.

(14) Welding personnel are qualified.

(15) We'd Hi story records _are adequate.

Within the areas inspected, no violations or deviations were identified.

7. Steel Structures and Supports (Units Al and A2)

The inspector examined work activities (welding and non welding) for thecontainment, steel structures within the containment, and steel structuresand supports outside the_ containment as described below to determine whetherapplicable code ard procecure requirements were being met. The applicablecode for the containment is the ASME Boiler and Pressure Vessel Code,Section III, Subsection NE,1974 Edition including Addenda through S74. .Theapplicable code for pipe supports is the ASME Boiler and Pressure VesselCode, Section III, subsection NF, 1974 Edition including Addenda throughS74. The applicable code for other structural steel is the AWS structuralwelding code DI.1, Revision 2-74.

a. Observation of Welding Activities

i- The inspector observed the below listed in process welds 'at various( stages of completion:i

UNIT' STRUCTURE / SUPPORT WELD STATUS

Al MS Restraint Support A1SRS00075 Welding fill passesand Platform,

| Al MS Restraint Support A1SRS00037A Weiding fill-passes'

and PlatformAl MS Restraint 3upport A1SRS00038B Welding fill passes,

i and PlatformI- Al- MS Restraint Support A1SRS00016 Welding fill passes

and PlatformAl ' MS _ Restraint Support A1SRS00026 Welding fill passes

and PlatformAl MS Restraint Support- AISRS00049 Welding fill passes

and Platform-

.

. . - - - .- . .

J . .

, ,

.

4,

Al MS Restraint Support AISRSC0050 Welding fill passesand Platform

Al Battery Room Beams 53.03 D2 Welds completePlatform and 53.1102 to- NDE in process

connecting angles,support angles andEmbeds (Atlas Dwg. E4)

Al Containment A1CS01018 Welding fill passes(Ring 9 to 10)

.A2 Pipe Support Weld X18-164-AP2-0 Welding fill passes

(Aux.-Bldg. Level 2) Dwg. A25-321-164-AP2-1

Al Drywell Vent . AIDWW00091 S1 Fitup and fill passwelding

Al . Drywell Vent AIDWW00090 S1 Fitup and fill passwelding

The inspector observed the work to determine whether::

(1) Work is conducted in accordance with a document which coordinatesand sequences operations, references procedures, establishes holdpoints, and provides for production and inspection approval.

; (2) Weld identification and location are as specified..

(3) Procedures, drawings, and other instructions - are at the workstation and readily available.

(4) WPS assignment is in accordance with applicable code requirements.

(5) Welding technique and sequence are specified and adhered to.

(6) Welding filler materials are the specified type and traceable tocertifications.j.

I (7) Weld joint geometry is in accordance with applicable procedure and' inspected.

(8) Alignment of parts is as specified.

(9) Preheat and interpass temperatures are in accordance with proce-dures.i

r (10) Electrodes are used in positions.and with electrical character-! istics specified.

!

(11) Welding equipment is in gcod condition. '

,

|. (12) Interpass cleaning is in accordance with applicable procedures.

<

1

.- , , .,. , -., .-. + - ..-, ~ ,v-- , - - - - . - - - - - - - , - , - - - - - - - ~

. .

.

5

(13) Temporary attachment are removed in accordance with applicableprocedures.

(14) Process control system has provision for weld repairs.

(15) Welding and inspection personnel are qualified.

(16) Weld history records are adequate.

b. Weld Heat Treatment

The inspector reviewed applicable preheat requirements and observedpreheat activities during observation of the welding listed in para-graph a. above. The work was observed to determine whether preheatcontrol procedures were being followed during field welding activities.

c. Weld Repair

The inspector examined weld repair activities for MS Restraint Supportand Platform Welds A1SRS00078R1, A1SRS00077R1 and A1SRS00076R1 todetermine whether weld repairs are conducted in accordance withapplicable requirements and specified procedures.

d. Examination of Non-Welding Activities

(1) The inspector observed the following activities:

ACTIVITY bHIT

Fitup of Box Beams Alat Welds AISRSC0048and AISR00047 r neMS Restraint Support

Storage of MS Restraint AlSupport Steel atAssembly location

Fitup of Cicsure Plate Albetween Drywell VentStructure Frames 5 and 9

(2) The inspector reviewed a sample of receiving inspection andmaterial test reports for the following MS Restraint SupportSteel.

;)'

. .,

.

6

Columns: 88-4-88-10BB-9BB-EBB-2

Box Beans: .BB-13

The activities and records were examined to determine whetherapplicable' requirements were being met in the areas of:

Receipt inspection and stcrageInstallation / erectionInspection and NDE

' use of qualifiea inspection personnel

Within the areas inspected, no violations or deviations wereidentified.

-8. Safety Related Structures - Review of Quality Assurance Implementing Proce-dures (Units Al and' A2)

The. inspector reviewed QA implementing procedures relative to safety related-structures to determine whether procedures are included or referenced in the'OA manual to assure that specific activities are controlled and performed in'accordance with NRC requirements. See paragraph 7 above for the applicablecodes.

a. The following documents were reviewed:

General Specification G-29C" Process Specifications for Welding, Heat Treatment, NondestructiveExamination, and Allied Field Fabrication Operations"

General Specification G-29M" Process Specifications for Welding, Heat Treating, Nondestructive,

Examination, and Allied Field Fabrication Operations"

CEP 5.04, Revision 6, " Work Packages"

l' CEP 9.08, Revision 4, " Process Control"

CEP 10.01, Revision 2, " Inspection"

CEP 7.02, Revision 8, " Receiving Inspection"'

CEP 13.02, Revision 4, " Storage and Preservation of Materials,-Components, and Systems"

,

CEP 17.01, Revision 5, " Quality Assurance Records"

Division of Construction QA Manual

I-

,- , - . . . . - . , , - . _ - - . - - . - _ - .

. _ _ . . . . .-. . - - .- - __. - .. . . _

. .'

.

7u

RS & PMI Manual

b. The documents listed in a. above were reviewed in the areas of:

(1)' Inspection and work procedures which identify hold points where->

witnessing or inspection is required.t: -(2) Receiving inspection procedures.

! (3) Storage, protection and issue procedures.

(4) Installation. procedures. ,

Within the areas inspected, no violation or deviations were identified.J

9. Review of QA Manual - Welding, Piping and Structural (Units A1.and A2)

I '

The inspector reviewed quality assurance procedures for welding activitiesas indicated below to determine whether procedures'have been established inaccordance with NRC requirements, SAR commitments and code requirements as-applicable. See paragraphs 6 and 7 for applicable codes.

ia. QA Manuals and referenced documents, as identified in b. below, were

reviewed to determine whether adequate QA - plans -and procedures,-i including QC procedures have been established (written, reviewed,

approved and issued) to assure accomplishment and - control of thefollowing activities relative to welding.

,

; (1) Organizational stiacture including qualifications, training andstop work authority'

t

(2) Audits -including procedures, checklists,: qualification of auditors

. scope, frequency - and

!

I (3) General . quality requirements relative to material specifications,test reports, procurement documents. deviations, and control ~ of-

j components, structures, and systems

(4) Work and inspection procedures including provisions for review,| approval, and control

(5) Control of material including traceability, handling, shipping,3 storage, and identification or nonconforming material-

.(6) Procedures for Control of Proces'ses including special processes<

, (7) ' Procedures for corrective action

[ (8) . Document control including control of QA manual and periodic~

review for adequacy of document control'.

4 -

*P

,. ~ - - - , .,- . , . . - . , 6 mm r w ,, #. y.- -.-m,.ye -_ ._ . _ - . . . ,,--....Ee.i-..-,'

.

. o,

.

e

8' _

(9) Test Control and control of test equipment

(10) Quality records

b. The following were reviewed:

(1) OEDC Quality Assurance Manual for ASME Section III Nuclear PowerPlant Components (NCM)

(2) Division of Construction Quality Assurance Manual

(3) Quality Assurance Program Requirements Manual

(4) Construction Engineering Procedures (CEP) Manual

(5) Standard Operating Procedures (SOP) Manual

(6) Division of Construction Quality Control Instructions (QCI) Manual

(7) G29M - Process Specifications for Welding, Heat Treatment, Nonde-structive Examination, and Allied Field Fabrication Operations

(B) G29C - Process Specifications for Welding, Heat Treatment, Nonde-structive Examination, and Allied Field Fabrication Operations

Within the areas inspected, no violations or deviations were identified.

10. Licensee Identifiea Items ~(50.55(e))

a. (Closed) Item 518, 519, 520, 521/80-05-03, RPV Shield . Wall ' WeldDeficiencies (NCR's HNP-A-087, HNP-A-108, 'HNP-A-109, HN P-A-115, . ' andSX-19). On February 15, 1980, TVA notified IE:II of a 50.55(e) itemconcerning deficient welds on the RPV shield wall. Interim reports

| were submitted on March 13, May 29,- September 24, and December 22,1980. :The final Construction Deficiency Report was - submitted June,2,1981. TVA submitted letters dated July 1, August 26, - and October 1,.

| 1981 stating that completion of all corrective. action would.Le later

j than reported in the final report. The reports have been reviewed and

|- determined to be acceptable by IE:II. The inspector held discussions[ with the-licensee and reviewed supporting documentation to verify.that

the corrective actions identified in the reports have been completed.,

The records reviewed included closed out'NCR's 087, 108, 109, 115 and-

SX-19; and weld records for welds A1PSW00164AR1, A1PSW00188AR2,.A1PSW00236BR1, ' A2PSW00166BR1, A2PSW00173AR1, and ~ A2PSW001978RI. In

! reviewing the TVA reports, the inspector noted that deficient condi-tions are discussed relative to Unit Al shield wall on site, Unit A2shield wall on site, and Unit B1 shield wall at the vendor's' plant. In-

actuality, the problems were with the Unit Al and tiers 1 and 2 ofUnit B1 at the site and~ tiers 3 and 4 of Unit B1 at the vendor's plant.Unit B1 shield wall was substituted for Unit A2 shield wall which wasnever constructed.

'

,

' 1

. ..

..

9

b. (0 pen) Item 518, 520/81-10-04, QA Documentation for Drywell FramedEmbedments. TVA has started on-site repair to Unit: A1 frames 5,6,7,8and 9. For these frames, 1004 visual and magnetici particle (MT) linspections were performed on all accessible structural welds. Ten ipercent of cadwelds were visually inspected. During this inspection, |

the inspector observed defect excavations in the following welds:

WELD DWG. STATUS

125F Atlas WM 66 Excavation MT inspected clear

179B Atlas WM64 Started with 3 indications onsurface - turned into one -still excavating -

138N Atlas WM66 Defect visually removed bysurface grinding

11. Inspection Followup Items (Unit A1)

(Closed) Item 520/81-15-02, Clarification of Stud Welding inspectionrequirements. The licensee has issued a Design Information Request clari-fying the difference in " Shear Connectors" and " Concrete Anchors." Theinspector has no further questions on this matter.

!

l

M

s